Method of and means for making containers



I June 14, 1938. e. A. MOORE METHOD OF AND MEANS FOR MAKING CONTAINERSFiled Oct. 14, 1935' BY j 3 find/Cow ATTORNEY Patented June 14, 1938 IUNITED STATES PATENT OFFICE METHOD OF AND LIEANS FOR MAKING CONTAINERSGeorge Arlington Moore, Louisville, Ky., assignor' to HumocoCorporation, Louisville, Ky., a corporation of Delaware ApplicationOctober 14,1935, Serial No. 44,857

9 Claims. (CI. 93-60) This invention relates to flanged articles of ingthe same in accordance with the present inmanufacture such as containersmade of paper vention; or other fibrous material, and more particularly.Fig. is a top plan view, with parts broken to a method of folding ablank of fibrous maaway, of one corner of a completed article;

5 terial to form a flanged article having angular Fig. 6 is a sectiontaken on line 6-6 of Fig. 5; 5 corners. Fig. '7 is a plan view, withparts broken away,

One of the objects of the present invention is of the female and footingdies employed in a .to provide a novel method of forming a flangedmachine for carrying out the method of the article from a flat blankofflbrous or other foldpresent invention; able material. Fig. 8 is asectional side elevation, with parts 10 Another object of the inventionis to provide a broken away, showing an intermediate position novelmethod of folding the flange and flange of the die members of saidmachine;'and, corners of an article wherein said comers are Fig. 9 is asectional side elevation, with parts folded in a novel manner. brokenaway, showing the positions of the die Still another object is toprovide a novel nieth- I members at the completion of the folding opera-15 0d of forming a container constructed of paper tion.

or other flbrous material and having angular The present inventioncomprehends a novel corners wherein the side walls are, seamless andmethod of forming or folding a blank into a integral with the baseportion of the container. flanged article, such as a container havingtwo A further object is to provide a novel method or more side wallswhich intersect at a com- 20 of folding the material of a blank adjacentthe paratively sharp angle, as distinguished from a corner of a flangeconstituted by a turned-up circular or similar curved wall container,wheremarginal portion of said blank whereby the folds in the flange willnot only be integral with the are symmetrically disposed with respect tosaid 1 base of the container but will also be continuous corner. orseamless. Containers thus produced are 25 A still further object is toprovide a simple and superior to others of a similar shape heretoforeinexpensive method of folding the marginal po p de in t the Walls f theSame are tion of a blank to form a flange or the side walls pervious toair and moisture and the container of a container, said method beingadapted to bel n s i s lf to the pa kin f n granular carried outautomatically, if desired, by the use stances without danger of leakage.In th illus- 30 of a small number of mechanical parts, the opertratedembodiment, a portion only of an article ation of which does not requirethe constant ator container having an angular corner is Shown. tentionof skilled attendants. by way of example. p v

The above and further objects and novel fea- It will be considered, forthe purposes of detures of the invention will more fully appearscrlption, that the illustrations of Figs. 1 to 6, in- 35 from thefollowing detailed description .when elusive, represent but one cornerof a rectangular taken in connection with the accompanying containerwhich comprises a blank I! having a drawing. It is to be expresslyunderstood, howcentral or base area l3 and a margin or flange ever, thatthe drawing is for the purpose of illust n 14 u r und s d a area-Preftration only and is not designed as a definition erablyr along linel5 prior to the folding operation to of the limits of the invention,reference being primarily had for that purpose to the appended behereinafter described in order that the upper claims. edges of thecorner folds to be formed will be In the drawing wherein like referencecharflush w edggs g i'g a thelateris urne up ocons tue es ewals 3:25;:refer to like parts throughout the several of the container a Ifdesired, blankl2 may'besco'red to form an 1 may; f external bead l6outlining base portion l3 for corner 0 y p y the purpose of facilitatingthefolding of said tio strength to the completed article or container.

n; E- 2 is a similar View of the bottom outer To facilitatethe foldingof the corner areas inface of the blank of Fi 'cluded in the right anglebetween lines a and e,

Figs. 3 and 4 show successive positions assumed the blank may also bescored along lines a to e.

the corners of the blank are trimmed 40 carrying out the method of thepresent invenblank, and for giving increased rigidity and 50 0 y theblank 1 F 8- 1 in h Pr s of 1' l inclusive, scores a, c and e producingslight 55 beads on the lower face of the blank, and scores b and dproducing beads on the inner face thereof. As will hereinafter appear,however, none of the above described scores are essential elementsin-practicing the present invention, but are merely illustrated anddescribed as elements of a preferred embodiment.

In paper containers, and containers comprised of like materialsheretofore provided, the corners are weakened by the provision of a seamin the flange or side walls thereof at or near said corners. In otherprior art containers, a single thickness of material is employed at thecorners, thus rendering the same susceptible to crushing under slightstresses, particularly in those wherein the material is weakened by thenecessary breaking down of the body or fabric thereof when the same isbent to form said corners. In many containers of the latter type,additional pieces of fiber or tape are secured about the corners'thereof by means of staples or a suitable adhesive for the purpose ofreinforcing the same in some degree, but this entails extra expense andlabor. By the method of the present invention, a container havingreinforced, seamless angular corners in the side walls thereof andhaving said side walls integral with the base of the container isadapted to be readily and inexpensively made from a single blank ofmaterial. The novel method proposed comprises folding the marginalportions I4 of blank I2 along the line or outer edge of. score IIi intoa position substantially perpendicular to base portion I3, therebyforming the side walls of the container. Simultaneously with the foldingof said side walls, the corner area included between lines a and e ofthe margin I4 of the blank is creased and folded along each of the linesa to e inclusive. Each of creases a, c and e approaches a verticalposition above the corner of base area I3, while creases b and d arecaused to move inwardly at a greater rate than the other three andbeyond the vertical, thereby forming two corner folds I, 2 and 3, 4.During the formation of said corner folds, creases b and d arepreferably guided in diverging paths so that the upper or inner surfacesof segmental areas I and 4 'may be brought into engagement with the sidewalls I4 adjacent said surfaces and at opposite sides of the corner.

For the purpose of maintaining .the flange and corner folds in positionafter the same have been formed, a suitable adhesive is applied to theinner -or upper faces of segmental areas I and 4 (Fig. 1) which, asalready noted, are caused to engage the side walls I4, and to the outerfaces of segmental areas 2 and 3 (Fig. 2) which engage the outersurfaces of areasl and 4, respectively. The adhesive employed ispreferably a thermoplastic lacquer adapted to be activated by heat andpressure without the application of a solvent. When said adhesive isrendered tacky by heat and pressure is simultaneously applied to thefolds, the engaging surfaces of said folds and side walls aresubstantially welded together.

One form of the novel mechanism for carrying out the method abovedescribed is illustrated in Figs. 7 to 9, inclusive, only that portionof the machine employed for folding one corner being shown. In the formillustrated, the machine comprises a female die member I! having ayieldingly supported footing die I8 engaging the inner walls thereof andadapted to reciprocate therein, a male pressing die I9, and a foldingand stripping die 20 surrounding andcontacting said pressingdie. Anysuitable mechanism, many of which are well-known in the art, may beprovided for imparting the desired reciprocating movement to dies I9 and20, and since such actuating mechanism constitutes no part of thepresent invention, it is believed to be unnecessary to illustrate anddescribe the same.

Female die I1 is provided with a central opening, the lower inner walls2| of which are vertical and are adapted to position and guide footingdie I8, the upper face of which corresponds in size and shape to thebottom of the container or article which it is desired to make. ,Theupper inner walls 22 of die I! are inclined upwardly and outwardly fromvertical walls 2I for the purpose of initiating the bending of themarginal portion I4 of blank I2 in the formation of the flange or sidewalls of the container being produced, the width of inclined surfaces22, as seen in Fig. 8, preferably being somewhat greater than the widthof flange I4 of blank I2. The angle of inclination or slope of walls 22is shown in the drawing to be substantially 45, but any suitable degreeof inclination may be employed, depending on the weight and quality ofthe material constituting the blank to be folded.

In order to crease the corner areas of the marginal portion of blank I2along lines a to e, inclusive, as desired, and to initiate the foldingof the same in the manner above described, each of the corner areas ofthe inclined walls 22 of female die I1 has two pyramidic raised portionsI, 2 and 3', 4'. Preferably, the surface along lines a and e, whichbound the corner areas of inclined walls 22, and line 0, which in theform shown bisects said corner area, have the same inclination as saidwalls, whereas lines b and d are inclined at a greater angle with thehorizontal. The operative surfaces I and 2' of one of the pyramidicraised portions slope downwardly in diverging directions from line oredge b to lines a and 0, respectively, and surfaces 3' and 4' of theother pyramidic raised portion slope downwardly in the same manner fromline or edge d to lines 0' and e, respectively. Line .0 is thus the lineof intersection of surfaces 2' and 3', and lines a and e' are the linesof intersection between surface 22 and surfaces I and 2', respectively.The angle of inclination of lines b, c andd' and hence the lateral slopeof surfaces I, 2', 3' and 4' will of course depend upon the slope ofwalls 22, said slopes bearing such relation to one another that when themargin I4 of blank I2 has been folded to the full line position shown inFig. 8, the combined areas of surfaces I to 4', inclusive, willaccommodate the corner area of said margin without wrinkling the same orplacing any portion thereof under tearing pressure.

Folding and stripping die 20 cooperates with female die IT to bend andconform the margin I4 of blank I2 to the shape of the various inclinedsiu'faces of die I! above described, and to crease the comer areasthereof along lines a to e, inclusive. The lower surface of folding die20 is machined to cooperate with the upper portion of die II, the lowerface of said folding die being inclined in the same manner as are walls22 of die I! and having recesses therein complementary to pyramidicportions I 2', and 3', 4'. When die 20 is moved downwardly to theposition shown in Fig.8 with the margin I4 of blank I2 interposedbetween it and the female die I1, it will be seen that the marginof saidblank will be turned up at an angle to the base portion I4 and thecorners will be creased and the folding thereof initiated substantiallyas illustrated in- Fig. 3 of the drawing.

For the purpose of completing the corner folds l, 2 and 3, 4 and fordirecting or guiding the same into engagement with the adjacentsidewalls II at opposite sides of the corner when said walls are drawninto vertical position, a recess 23 extending a short distance on eachside of the internal corners of female die I1 is provided. Said recessis bounded by two triangularly shaped walls 24 which have the samedirection of slope as walls 22 but a much greater degree of slope thansaid latter walls, and by two walls 25 which are included in planesperpendicular to vertical walls 2! of die and slopedownwardly from theextremities of said recess toward the corner of die I]. When either dieH3 or I9 is in position to bound the recess 23, a pyramidal cavity isformed in which the corner folds of the container are adapted to beguided and pressed into final position.

Pressing die i9 and footing die iii are adapted to operate within diesl1 and 20, the dimensions of said pressing die in a horizontal planebeing less than those of the footing die by an amount equal to twice thethickness of blankl2. Dies I8 and I9 serveto clamp blank l2 in positionand to carry the same downwardly into die I! whereby flange M of saidblank is drawn and folded in the manner heretofore described. Ifdesired, groove l6 may be impressed in blank l2 by the operation of diemembers I!) and I8, the former being provided with a peripheral bead 26on the face thereof, while the latter has a groove 21 adapted tocooperate with said bead. Groove 21 is preferably sufliciently large toaccommodate bead 26 and the material of blank l2 which forms bead l6 sothat the central portions'of dies l8 and I9 will engage opposite facesof said blank during the flange and corner folding operation to therebyfirmly clamp the blank in position.

In the operation of the above described apparatus, blank I2 is placed ontop. of female die I 1 and footing die l8, which latter is normally heldin the dotted line position (Fig. 8) by suitable spring means (notshown), the initial position of said blank also being shown by dottedlines in Fig. 8. Pressing die l9 and folding and stripping die 2|] arethen moved downwardly together, bead 26 of the latter first engagingblank l2 to form groove l6 about the base portion l3 of the blank. Uponfurther downward movement of the,pressing and folding dies,footing dieI8 is also forced downwardly and marginal portion ll of blank I2 isdrawn toward a vertical position within female die l1. When the partshave reached the full line positions shown in Fig. 8, margin H of theblank is clamped between folding die and female die l1, whereby thecorner areas a, e of said margin are definitely creased along lines a.to e, inclusive, and the entire marginal portion is turned up tosubstantially the position illustrated in Fig. 3. Folding die 20 isthereupon withdrawn (Fig. 9) to free margin ll of the blank as pressingdie l9 continues its downward movement, drawing flanges l4 into verticalposition between die l9 and the vertical walls 2| of die II. Thiscontinued downward movement of the pressing and footing dies andconsequent drawing of flange i4 causes creases a, c and e to movenaturally into substantial coincidence in a substantially verticalposition directly above the corner of base area I3, which movement inturn causes the leading edges or creases b and d of folds i. 2 and 3, 4,respectively. to engage the sidewalls shown in Fig. 5. Due to the slopeof walls 24,

each increment of downward movement of die l9- after the folding of theflange is completed results in the application of a lateral outwardpressure against the corner folds. Simultaneously with the applicationof such pressure, heat may also be applied to the folded portions bysuitable heating means 28, such as steam conduits or electric heatingelements, which may be placed in either or both of the die members I!and IS. The thermoplastic adhesive which is placed on portions of thecorner areas of the blank prior to the folding operation, as heretoforedescribed, becomes tacky by the application of said heat and thepressure causes the same to flow into the pores and crevices of thematerial and weld the engaging surfaces of the folds and side wallstogether. Upon the retraction of pressing die IS, the upper edgeof theside walls ll of the container engages the lower edge of folding andstripping die 20 which serves to strip the completed container from thepressing die. The container is thereafter removed and another blank isinserted, either by hand or by suitable well known mechanism (notshown).

There is thus provided a novel method of forming, from a blank of fiberor like material, a container having angular corners and seamless sidewalls integral with the base portion or bottom thereof, said side wallsthus being impervious to air and moisture and also leak-proof. The novelmethodof folding the corners of said blank also results in the formationof a reinforced corner structure. There is also provided novel means forpracticing said method, which means is inexpensive and lends itselfreadily to largescale production.

Although only one embodiment of the invention has been illustrated anddescribed, it is to be expressly understood that the same is not limitedthereto but that various sizes and shapes of articles or containers maybe made by the novel method comprehended. Itwill also be understood thatthe corner folds I, 2 and 3, 4 may be folded to engage the outersurfaces of walls ll, if desired. Various changes may also be made inthe means employed in carrying out the meth- 0d of the invention, aswill now be apparent to those skilled in the art. Reference will beprimarily had to the appended claims for a definition of the limits ofthe invention.

What is claimed is: 1. The method of making a flanged article from-ablank which consists in drawing the marginal portion of the blank toform a flange and define a rectangular base area, the flange beingadapted to' form four side walls of the article, drawing the portions ofthe flange intermediate each side wall along-five lines radiating fromeach corner of the base area gular folds at each corner, andsimultaneously welding together the material of each fold and to formtwo trianthe fold to the side wall to form reinforced and tainer, andsimultaneously drawing the corner areas of said marginal portion, saidareas being first creased and thereafter drawn to engage said side wallsat each side of the corners of said container, while welding the drawnareas to the side wall at each side of the corners of the. container.

3. In combination, a female die, a rectangular male die adapted toextend into said female die, and a second male die surrounding saidfirstnamed male die, said second male die and said female die havingcoacting surfaces for forming folds in a blank at the corners of thelatter and said female die having recesses at the corners thereof forreceiving the folds formed in the blank by said second male die and thefemale die.

4. In combination, a female die having an opening with perpendicularside walls therein, a male die adapted to extend into said opening, anda die member surrounding said male die and adapted to move relativelythereto, said die member and female die having coacting surfacesadjacent the intersection of said perpendicular walls for forming foldsin a blank and the walls of said female die being cut away adjacent saidintersection to provide a recess for receiving the folds formed in theblank by the coacting surfaces of said die member and female die.

5. In combination, a female die, a male die adapted to be moved to drawa .blank into said female die, and a die member surrounding the maledie, said die member and female die having coacting surfaces for formingtriangular folds in said blank and said female die having portions ofthe walls thereof cut away to provide a recess for receiving said foldsas the male die moves into the female die.

6. The method of making a flanged article from' a blank which comprisesdrawing a marginal portion of the blank to form a flange having anangular corner and forming adjacent side walls of the article, drawingthe portion of the flange adjacent said corner along five linesradiating from the base of said corner to form two triangular folds, andsimultaneously pressing the adjacent surfaces of each fold together andthe folds against the side walls to form reinforced and seamlesscorners.

7. The method of making a container which comprises subjecting a blankto the action of cooperating male and female die members whereby amarginal portion of said blank is progressively drawn into flangedrelation with the central portion thereof to form the side walls of thecontainer, and simultaneously drawing a corner area of said marginalportion, said corner area being first creased and thereafter drawn toengage said side walls at each side of an angular corner of thecontainer.

8. The method of forming a container from a blank which comprisesapplying a thin, dry film of thermoplastic material having adhesive properties to said blank, drawing the blank into the desired shape,simultaneously drawing portions of the blank into overlapping relation,and applying heat and pressure to said overlapping portions foractivating said thermoplastic material and pressing the same into theinterstices of the engaging surfaces of said overlapping portions.

9. The method of forming a container, having a bottom and side walls,from a blank comprising fibrous materials which includes applying athin,

dry film of thermoplastic adhesive to portions of said blank, diedrawing the blank to form said side walls and to overlap portions of thelatter, and applying heat and pressure to the side walls for activatingsaid adhesive and pressing the same into the interstices of theoverlapping portions of said side walls.

GEORGE ARLINGTON MOORE.

